Foaming compositions



United States Patent M 3,311,573 FQAMHNG CQMPUSHTIGNS Neil Bonnette Graham and James David Murdock, St.

Hiiaire, Quebec, Canada, assignors to Canadian llndustries Limited, Montreal, Quebec, Canada, a corporation of Canada No Drawing. Filed Apr. 23, M63, Ser. No. 274,968 Claims priority, application Great Britain, Nov. 27, 1962,

44,863/62, 44,865/62, 44,867/62; Feb. 5, 1963,

15 Claims. (Cl. 260-25) This invention relates to novel compositions suitable for the production of foamed cellular polymeric materials novel foaming processes employing such compositions and the novel foamed cellular polymeric materials obtained therefrom.

It is known to manufacture solid foamed polymeric materials by expanding polymeric materials with numerous gas bubbles to yield products having densities as low as one or two pounds per cubic foot. Such polymeric foams are known in both rigid and flexible forms, and typical examples thereof are the polyurethane and polystyrene foams. The former are capable of being foamedin-place to fill cavities of irregular shape, and they may also be dispensed from mixing machines to coat articles with thick insulating blankets. Their isocyanate ingredients are, however, undesirably toxic under some conditions. The polystyrene foams, on the other hand, 'are not conveniently foamed-in-place since requiring external heating for this purpose and, in addition, they do not flow easily into complex cavities and do not bond to surfaces.

It is an object of this invention to provide new foaming compositions which are suitable for the production of foamed-in-place polymeric materials and the ingredients of which do not present the toxicity problems encountered with the ingredients of polyurethane foaming compositions. Another object of the invention is to provide new compositions which yield polymeric foams having a wide variety of properties suitable for many end uses. Additional objects of the invention will appear hereinafter.

The new foaming compositions of this invention comprise at least one polymerizable vinyl ether containing at least two vinyl groups per molecule, at least one vinyl ether-reactive member selected from the group consisting of phenolic compounds and epoxidized materials containing at least one epoxide group per molecule, a foaming agent and an acidic catalyst.

Any foaming agent may be used in the compositions, particularly those which have been proposed for use in conjunction with polyurethane materials for the production of foamed or cellular materials. Volatile foaming agents are particularly suitable.

As suitable acidic catalysts, there may be used, in particular, those acidic catalysts which have been proposed for the polymerization of vinyl ethers and, more particularly, those which have been proposed for the polymerization of vinyl ethers having two vinyl groups. Especially useful catalysts are the strong acidic ones.

Preferred foaming compositions according to this in vention comprise, in addition to the foaming agent and acidic catalyst, at least one polymerizable vinyl ether containing at least two vinyl groups per molecule in admixture with the following vinyl ether-reactive materials in the proportions indicated:

(a) A compatible phenolic compound and, optionally, minor proportions of a compatible aliphatic monohydric or polyhydric alcohol and/or epoxidized material containing at least one epoxide group per molecule, the proportions of the ingredients being preferably such that the number of hydroxyl groups provided by said phenolic Patented Mar. 28, 1967 compound and alcohol, if the latter is present, is less than the number of vinyl groups provided by said vinyl ether together with the number of epoxide groups provided by said epoxidized material if the latter is present;

(b) A compatible phenolic compound and a corn patible epoxidized material containing at least one epoxide' group per molecule, the proportions of the ingredients being preferably such that the number of hydroxyl groups provided by said phenolic compound is not greater than about 75% of the combined number of vinyl and epoxide groups provided by said vinyl ether and epoxidized material, respectively; or

(c) A compatible epoxidized material containing at least one epoxide group per molecule.

Under the influence of the catalyst and in the presence of the foaming agent, the polymerizable vinyl ether and the vinyl ether-reactive compound or compounds undergo chemical reaction leading to the formation of polymeric foamed materials of Widely varied properties and utilities. It has been found that organic bases such as the dimethyl tertiary amines derived from cononu-t fatty acids can be used to retard the reaction of the foam-forming ingreclients of the compositions.

wherein n is an integer having a value of at least 2, R and R 'are members selected from the group consisting of hydrogen and alkyl radicals, R is a member selected from the group consisting of hydrogen, halogen atoms and hydrocarbyl radicals, R and R taken together form a member selected from the group consisting of two hydrogen atoms, two alkyl radicals and one a lkylene or substituted alkylene radical, R is a member selected from the group consisting of hydrogen and alkyl radicals, andA is a linking group having a valence equal to n.

Examples of the aforementioned vinyl ethers are: divinyl ether, di-isopropenyl ether, butanediol divinyl ether, propylene oxide/polyol condensates of the formulae and I CH3 CH2 O 110 OH: 1120 CH H (")H-CHz-OOC-CIJI 511 1,2 ethanedioxy bis (3',4' dihydro ZH pyran-2- carbonyl) of the formula bis-(3,4-dihydro-2H-pyran-2-methyl) succinate of the formula 1,2-bis(3',4'-dihydro-2'H-pyran-2'-oxy)ethane of the formula 1,2-bis(3',4'-dihydro-2H-pyran-2-oxy)ethane of the forformula 1,Z-ethanedioxy-bis(3',4-dihydro-5'-methyl Z'I-I pyran- 2'-carbonyl) of the formula 1,2-bis(3',4'-dihydro-5'-methyl 2'H-pyran-2-oxy)ethane of the formula l,l-bis(3',4-dihydro 5' methyl-2'H-pyran-2'-methoxy) ethane of the formula toluene 2,4 bis (3,4 dihydro-2H-pyran-2'-methyl) carbamate of the formula the tri-ester derived from three moles of 2-hydroxymethyl-3,4-dil1ydro-2H-pyran and one mole of orthophosphoric acid, and the esters derived from Z-hydroxymethyl- 3,4-dil1ydro-2H-pyran and organic polybasic acids as maleic and adipic acids. It has been found that the straight chain vinyl others are more reactive than branched chain or cyclic vinyl ethers. It is desirable that the vinyl ethers do not boil during the foam-forming reaction.

The phenolic compounds used as ingredients in the foaming compositions are those aromatic compounds which contain one or more hydroxyl groups in their molecules such as phenol, alkyl-substituted phenols, e.g., cresols, halogen-substituted phenols, e.g., 2,4,5-trichlorophenol, resorcinol, phloroglucinol, catechol, hydroquinone, 2:2-di-p-hydroxy-phenylpropane, low molecular weight phenol-terminated polycarbonates, the condensation products of phenols with aldehydes and ketones, etc.

The aliphatic monohydric and polyhydric alcohol ingredients of the foaming compositions of this invention include amyl alcohol, Z-ethylhexyl alcohol, nonyl alcohol, n-decyl alcohol, polypropylene glycol, caster oil, sugar alcohols, alkyl and acyl cellulose derivatives, polyether condensates of polyhydric alcohols and olefin oxides such as the polypropylene oxide condensates of hexahydroxy sugar alcohols and propylene oxide, ethylene glycol, 1,5- pentanediol, glycerol, 1,2,6-hexanetriol and hydroxylcontaining esters and polyesters obtained by condensation of polyhydric alcohols and polybasic acids. The proportions of condensating ingredients in said hydroxylcontaining esters and polyesters may range from one mole of polyol for each carboxylic acid group in the acid to one mole of polycarboxylic acid for each hydroxyl in the polyol. The first limit gives an ester containing free alcoholic hydroxyl groups whereas the second gives an ester containing carboxylic acid groups; in between these limits, polyesters are formed which contain both hydroxyl and carboxylic acid groups.

By epoxidized materials containing at least one epoxide group per molecule are meant compounds containing at least one group of the formula;

per molecule. Examples of such compounds are epichlorohydrin, styrene oxide, diallyl ether monoxide, cyclohexene oxide, glycidyl phenyl ether, glycidyl stearate, dipentene dioxide, vinyl cyclohexene dioxide, polya l glycidyl ether, diphenylolpropane diglycidyl ether, epoxidized polybutadiene, epoxidized styrene-butadiene 00- polymers, the resinous condensates of epichlorohydrin and aliphatic or aromatic polyols such as glycerol or 2:2- di-p-hydroxyphenyl propane, etc.

Volatile foaming agents suitable for use in the foaming compositions of the invention are those which are soluble or dispersible in the other ingredients of the foaming compositions and are sufliciently volatile that they vaporize during the formation of the foamed polymeric materials. The heat of the catalyzed polymerization reaction causes the foaming agent to boil, and the vapour forms bubbles which expand during the polymerization reaction to give a low density, foamed polymerized mass. Preferred foaming agents are the halogenated hydrocarbons such as trichloromonofluoromethane, dichlorotetrafluoroethane, trichlorotrifluoroethane, dibromodifluoromethane, dichlorohexafluorocyclobutane, methylene chloride, chloroform, trichloroethylene, carbon tetrachloride and perchloroethylene.

The strong acid catalysts suitable for promoting the reaction of the polymer-forming ingredients of the foaming compositions include the strong proton-donating acids, such as p-toluenesulphonic acid, and the Lewis acids such as trimethoxyboroxine and boron trifiuoride conveniently employed as the etherate, BF .(C H O. Compositions containing very reactive vinyl ethers such as butauediol divinyl ether can be catalyzed by p-toluene sulphonic acid but a Lewis acid catalyst is preferred for those compositions containing 3,4-clihydro-2H-pyranyl compounds including the 3,4-dihydro-2H-pyran-2-methyl (3,4-dihydro-2H-pyran-2-carboxylate) referred to hereinafter.

It is possible to control the polymerization reaction by employing catalyst combinations e.g. p-toluene sulphonic acid and boron trifluoride or boron trifluoride and trimethoxyboroxine. Other materials which are suitable as catalytic ingredients are ferric chloride, stannic chloride, phosphorus pentachloride, phosphoric acid, perchloric acid, acetic acid, trifiuoroacetic acid, trichloroacetic acid, fiuoboric acid, boron trifluoride dihydrate, hydrogen fluoride, antimony penta-fluoride, hexafluorophosphoric acid, lead fluoborate, antimony fluoborate, sulphuric acid and silicotungstic acid. The solvent in which the catalyst is dissolved also affects the catalyst reactivity, polypropylene glycol solutions of BF .(C H O being less reactive than xylene solutions of said catalyst. Suitable catalytic amounts range from 0.005% to 2.0% by weight of the compositions, but these amounts are not limitative since the amount of catalyst should be adjusted to the temperature of operation and the foam induction period required. When Lewis acids are used as catalysts in foaming compositions devoid of phenolic or alcoholic ingredients, it is often advantageous to incorporate into the compositions small amounts of co-catalysts such as water, alcohols or carboxylic acids.

Suitable flame-retardants for incorporation in the foaming compositions include trichloroethylphosphate, 2:2- bis-(3',5'-dibromo-4'-hydroxyphenyl) propane, chlorendic acid, and polyvinyl chloride, with or without antimony oxide. The phenolic compound serves both as flameretardant and vinyl ether-reactive material.

The preferred surfactants are those of the silicone type, examples of which are disclosed in Belgian Patent Nos. 582,362 and 584,089, i.e. being of the siloxane oxyalkylene copolymer type.

In the above list of vinyl ether-reactive materials, preferred proportions are indicated. However, the proportions of such reactive materials in relation to proportions of vinyl ethers may vary considerably. The use of widely differing proportions leads to the formation of foamed materials of differing properties, e.g. different compression strength, density and texture. In order to obtain foamed materials of advantageous properties and of particular utility, it is often necessary to vary the proportions of vinyl ether and vinyl ether-reactive material according to the nature of the reactive material used.

Referring, then, to particularly preferred proportions of the ingredients of the foaming compositions of this invention, it has been found that in the case of compositions containing ether-reactive material (a), preferred compositions comprise at least 50% by weight of vinyl ether, said vinyl ether always being present in the aforementioned proportion in relation to the other ingredients, the phenolic ingredient in proportion restricted in the manner hereinbefore specified, and from 2% to 30% by weight of the foaming agent, the remaining constituents such as surfactant, aliphatic monohydric or polyhydric alcohol and epoxidized material each being present in an amount less than about 5% by weight.

The polymerization of vinyl ethers containing at least two vinyl groups per molecule under the influence of strong acid catalysts is very rapid with the result that dark coloured foams of poor structure can often be ob tained. However, the admixture of phenolic compounds with the vinyl ethers shortens the induction period of the foams and slows up their rate of set so that splits are less frequent and lighter-coloured foams of improved structure are obtained.

Preferred compositions containing ether-reactive material (b) are those in which the combined weight of the vinyl ether and the epoxidized material is at least 50% of the weight of the compositions, the amount of phenolic 6 compound being such that the number of hydroxyl groups provided thereby is not greater than about 75% of the combined number of vinyl and epoxide groups provided by the vinyl ether and epoxidized material, respectively, the amount of foaming agent being from 2% to 30% by Weight and the remaining constituents such as flameretardant and surfactant each being present in an amount less than about 5% by weight.

The incorporation of epoxidized material into foaming compositions containing the vinyl ethers and the phenolic compounds results in foams with improved characteristics when compared to foams obtained from said compositions devoid of epoxidized material. The inclusion of the epoxide-containing material indeed results in lighter-coloured foams with excellent tough skins whereas foams obtained from compositions containing no epoxide ingredient often have friable brittle skins. The epoxidecontaining compositions also give more resilient foams.

Desirable compositions containing ether-reactive material (c) comprise 5% to 75% by weight of the vinyl ether, to 10% by weight of epoxidized material containing two or more epoxide groups per molecule or a mixture of such a polyepoxide with a monoepoxide, in which case the number of epoxide groups provided by said monoepoxide is less than three times the combined number of vinyl groups and epoxide groups provided by said vinyl ether and polyepoxide, respectively, and from 2% to 30% by Weight of foaming agent, the remaining ingredients such as surfactant and flame-retardant being present in amounts less than about 15% by weight.

The admixture of epoxidized material with the vinyl ethers results in foams which are whiter and usually have better skins than foams based on vinyl ethers alone. However, when the amount of epoxide ingredient exceeds about 25% by weight of the compositions, the resulting foams tend to split. When splitting occurs with compositions containing a boron trifluoride catalyst, the splitting of the foams may be eliminated by using as catalyst a combination of boron trifluoride and trimethoxy boroxine.

The ingredients of the foaming compositions may simply be mixed by stirring in a vessel and then quickly poured into a mould. They may also be mixed in the space which is to be filled with foam if it is suitably shaped. When such stirred mixing is used, it is highly desirable that a surfactant be added to the compositions in order to give foams of small bubbles. However, a surfactant is not always essential.

EXAMPLE 1 As previously mentioned, the polymerization of vinyl ethers containing at least two vinyl groups per molecule under the influence of Lewis acid catalysts is very rapid so that dark-coloured foams of poor structure are often obtained. However, the addition of phenolic compounds shortens the induction period, slows up the rate of set so that splits are self-healing, and yields lighter-coloured foams of improved structure. This is illustrated in Table V where the foaming of compositions containing increasing amounts of 2:2-di-p-hydroxyphenyl propane is described.

The foams were produced by dissolving powdered 2:2- di-p-hydroxyphenylpropane in 3,4-dihydro-2H-pyran-2- methyl-(3,4-dihydro-2H-pyran-2-carboxylate) while heating at C. for 30 minutes, cooling, and adding a silicone surfactant of siloxane oxyalkylene copolymer type and a portion of the foaming agent (trichloromonofiuoromethane) to form a first mixture. A second mixture containing the boron trifluoride etherate dissolved in polypropylene glycol of molecular weight 2025 and the remainder of the foaming agent was then prepared. The two mixtures Were blended using a high speed stirrer and poured into moulds.

TABLE 1 Force required for 10% Distilled 3.4- com ress'on, lb h 1 dihydro-2H- Siloxane oxy- Boron trifluop l S lmc pyran-2methyl- 2:2 di-p-hy- Triohloroallrylene copolyride 10% solu- Polypro- (3,4-dihydrodroxyphenylmonofluoromer type silition in poiypylene Induction Density, I II ZH-pyran-Q carpropane, g. methane, g. cone surfactant, propylene glyglycol, g. period lbs/it.

boxylate), g. g. col solution, Perpendlcu- Parallel to lar to direcdirection of tion of rise rise 190 50 0. 5 0. 5 10 Composition charred and not rise 190 10 50 2. 6 min- Composition charred and id not rise 100 50 2.0 2. 5 1 55 See Composition rose 4 in.

charred 190 30 50 2. 0 2. 5 10 110 see. Cnnposition foamed with arkenin and s l't 190 40 60 2. 0 2. 5 1D 2% min- 1.86 8% p l i 190 60 50 2. 0 2. 5 10 39 sec. 2. 2 13. 9 I 30. 3

The bottom composition produced a foam of good characteristics.

EXAMPLE 2 MIXTURE B G. 200 of Crude y -PY 3 -(3 10% boron trifiuoride in polypropylene glycol dihydro-2H-pyran-2-carboxylate) were heated at 130 C. (M W 2025) 3 5 while 50 g. of powdered 2 2-di-p-hydroxyphenylprop ne Trichloromonofluommethane 25 were added and dissolved. The mixture was cooled to room temperature and 2 g. of siloxane oxyalkylene copolymer type silicon surfactant and g. of trichloromonofluoromethane foaming agent were added.

A second mixture of 3.5 g. of a 10% solution of boron trifiuoride in polypropylene glycol of 2025 molecular weight and 30 g. of trichloromonofiuoromethane was prepared. The two mixtures were blended for 5 seconds using a high speed stirrer and then poured into a 7" x 7" x 12" mould. After a total induction period of 16 seconds, the foam rose to a height of 15 inches. The overall foam density was 1.7 lb./ft. and the core density was 1.5 lbs./ft. The foam was anisotropic, requiring 16 lbs/inch to produce a 10% compression parallel to the direction of the rise and 6 lbs/inch to produce a 10% compression perpendicular to this direction.

Another foam prepared from a similar recipe had a constant of thermal conductivity K of 0.13 Btu. per sq. ft. per hour per degree F. per inch.

EXAMPLE 3 Preparation of Novolak resin A mixture of phenol (3120 g), distilled water (312 cos), 37% aqueous formaldehyde (2220 g.) and oxalic acid dihydrate (24 g.) was placed in a 12 litre four-necked flask equipped with condenser, stirrer and liquid and vapour thermometer. The mixing reaction was endothermic and the mixture cooled to 5 C. The mixture was heated under reflux for 30 minutes and then a further 24 g. of oxalic acid dihydrate were added. The mixture was heated under refiux for an additional hour. At this stage, a heavy white material separated. Then 6 litres of cold water were added, the stirrer was removed and the mass was allowed to cool to room temperature. As much as possible of the water was siphoned off, the remainder (1 litre) being distilled ofi under vacuum until the temperature reached 120 C. The Novolak remaining in the flask weighed 3100 g.

Preparation of foam Two mixtures were made up as in Example 2.

MIXTURE A G Crude 3,4-dihydro-2H-pyran-Z-methyl-(3,4-dihydro- ZH-pyra'n-Z-carboxylate) 200 Mixture B was poured into Mixture A and blended for 10 seconds before pouring into a 7" x 7" x 12" mould. After an induction period of 31 seconds, the foam rose 12 inches. The overall density was 2 lbs/ft. and the core density was 1.8 lbs/ftfi. The force needed to give 10% compression was 16 lbs/inch parallel to the direction of rise and 6.5 lbs/inch perpendicular to it.

EXAMPLE 4 The following two mixtures were prepared and blended as in Example 3 to produce a foam.

MIXTURE A G Crude 3,4-dihydro-2H-pyran-2-methyl-(3,4-dihydro- 2H-pyran-2-carboxylate) 200 (M.W. 2025) 3.5 Trichlorornonofluoromethane 30 A block of foam of core density 1.8 lbs/ft. was obtained after an induction period of 13 seconds. The force needed for 10% compression was 16 lbs/inch parallel to the direction of rise and 5.8 lbs/inch perpendicular to it. The foam was self-extinguishing by ASTM- 1692-59-T due to the presence therein of 2:2-bis(3,5'- dibrorno-4-hydroxyphenyl)propane.

EXAMPLE 5 The following two mixtures were prepared and blended as in Example 3 to produce a foam.

MIXTURE A G. Crude 3,4-dihydro-2H-pyran-2-methyl-(3,4-dihydro- ZH-pyran-Z-carboxylate) 200 Novolak resin 30 2:2-bis(3',5'-dibromo-4-hydroxyphenyl) propane 50 Siloxane oxyalkylene copolymer type silicone surfactant 2 Trichlorornonofluoromethane 25 After a 12 second induction period, the foam rose 11 /2 inches in the mould. The core density was 1.9 lbs./ft. and the force needed for compression was 22.6 lbs/inch parallel to the direction of rise and 9.2 lbs./ inch perpendicular to it. The foam was self-extinguishing by ASTM-1692-59-T.

EXAMPLE 6 When foaming compositions are employed in conventional foam-dispensing equipment, it is desirable to have as much of the polymerizable mixture as possible dissolved in the foaming agent to give two streams which do not differ too greatly in viscosity. In this example, p-octyl phenol was used since it is soluble in trichloromonofiuoromethane.

Two mixtures were prepared and blended for seconds, before pouring into a 7" x 7" x 12" mould. After 63 seconds, foaming occurred to give a foam with the following properties: Density overall 2.3 lbs./ft. core density 2.0 lbs./ft. force for 10% compression 17.3 lbs./inch parallel to the direction of rise and 6 lbs/inch perpendicular to it. The two mixtures had the following composition:

MIXTURE A G Crude 3,4-dihydro-ZI-Ipyran-Z-methyl-(3,4-dihydro- ZH-pyran-Z-carboxylate) 200 2:Z-di-p-hydroxyphenylpropane 50 MIXTURE B Trichlor'omonofluoromethane 50 p-Octyl phenol 25 Siloxane oxyalkylene copolymer type silicone surfactant 2.5 10% boron trifluoride in polypropylene glycol (M.W.

EXAMPLE 7 Two mixtures were prepared and blended as in EX- ample 3.

MIXTURE A Crude 3,4 dihydro-2Hpyran-2-methyl-(3,4-dihydfo- ZH-pyran-Z-carboxylate) 200 Foaming occurred after 80 seconds to give a light coloured foam which, though not "self-extinguishing, was very slow-burning because of the effect of the 2,4,5- trichlorophenol. It had a density of 3 lbs./ft. The force required for 10% compression was 14.4 lbs/inch parallel to direction of rise and 5.9 lbs/inch perpendicular to it.

EXAMPLE 8 Two mixtures were prepared and blended as in Example 3.

MIXTURE A G Crude 3,4-dihydro-2H-pyran-2-methyl-(3,4-dihydro- 2H-pyran-2-carboxylate) 190 2:2-di-p-hydroxyphenylpropane 60 Low molecular weight resinous condensate of 2:2-dip-hydroxyphenyl propane and epichlorohydrin 10 10 MIXTURE B 10% boron trifiuon'de in polypropylene glycol (M.W.

2025) 2.5 Trichloromonofiuoromethane 50 Siloxane oxyalkylene copolymer type silicone surfactant 2 The resulting foam had a density of 2.2 lbs./ft. The force needed to produce 10% compression was 30.3 lbs./ inch parallel to the direction of the rise and 13.9 lbs./ inch perpendicular to it.

EXAMPLES 9 TO 23 Fifteen foaming compositions were prepared, each including the following mixture:

G. Crude 3,4-dihydro-2H-pyran-Z-rnethyl-(3,4-dihydro- ZH-pyran-Z-carboxylate) 20 2:2-di-p-hydroxyphenylpropane 5 Trichloromonofiuoromethane 5 Siloxane oxyalkylene copolymer type silicone surfactant 0.5

and each in addition containing a different catalyst. The fifteen catalyst compositions were as follows:

TABLE II Proportion of Catalyst Ingredients Ingredient respectively,

grams A Phosphorus pentachloride, boron trifluoride 1/1/9.

etherate, dicthylene glycol. B Orthophosphoric acid, boron trifiuoride 0.5/2/10.

etherate, diethylene glycol. C Acetic acid, borontrlfluoride etherate, dl- 0.5/1/5.

ethylene glycol. D- Trichloroacetic acid, boron trifluorlde ethe- 1.5/1.5/5. rate, diethylene glycol.

E Trifluoroacetic acid, boron trifluorlde ethe- 1/1.5/5.

rate, diethylene glycol. F Sulphuric acid, boron trifluoride etherate, 0.25/0.75/10.

dlethylene glycol. G Silicotungstic acid, boron trifluoride etherate, 0.5/1/5.

diethylene glycol. H"--. Stannic chloride, boron trifluoride dihydrate, 1/0.5/10.

diethylene glycol. I Stannic1 chloride, perchloric acid, diethylene 1/O.5/20. yco.

J Perehloric acid, boron trifluoride etherate, 0.5/0.3/8.

diethylene glycol. K--. Fluoboric acid, diethyiene glycol 2/8. L--." Stannic chloride, dlethylene glycol 1/9. M Stannic chloride N Hydrogen fluoride, diethylene glycol 5/5. 0..... Boron trifluoride/phenol complex, diethylene 5/5.

glycol.

Measured amounts of the catalyst were added with 5:)

' stirring to the first mixture contained in a 250 cc. paper TABLE III Amount of Induction Height of Example Catalyst Catalyst Period, Foam, in drops seconds inches 1 1 1 2 EXAMPLE 24 Butanediol-l,4-bis-(3,4 dihydro-2H-pyran-2-yl) 100 g. of crude 3,4-dihydro-2H-pyran-2-methyl (3,4- f 16 dihYdrO-ZH-pyran-Z-carboxylate) wer mixed with 25 g. P P 8 of para-nitrophenol and heated at 65 C. to effect solu- TilchloromOnofiuoromethane 5 tion. 20 g. of trichloromonofluoromethane and 1.25 g. 5 slloxane oxyalkylene copolymer type slhcone of a siloxane oxyalkylene copolymer silicone surfactant 'surfaciam T "7'"? were added and the mixture stirred to give a solution. Boron Q 10% methylene 1.75 ml. of a solution of fluoroboric acid (made by diluting a 40% aqueous solution to 10% by adding polypropyleneglycol) was added and after stirring for 50 10 The first four ingreqlems were mixed for 10 secolids seconds there was obtained a foaming mixture which rose i i mfiuonde catzilyst F added Wlth and set solid in a further five seconds to give a yellow After an Induction penod of 30 slightly coarse foam which was badly discoloured at its ends n'gld bntfle foam was Produced centre.

EXAMPLES 25 w as 15 A series of fourteen foams were prepared containing EXAMPLE 40 2: 2-di-p-hydroxyphenyl propane and different vinyl ethers using the following procedure. The vinyl ether, 2:2-di-p- The trivinyl ether of a propoxylated phenol-aldehyde hydroxyphenyl propane, the s1loxane oxyalkylene copoly- 20 condensate was prepared as follows. The propoxylated rner type sllicone surfactant, and the trichloromonofluorophenol-aldehyde cond ns TIiOl f methane foaming agent were mixed together. The boron 440 average molecular weight was treated with acetylene trifluoride catalyst was then added and the mixture was at 180-190 C. and at a pressure of 200-250 p.s.i. in the poured into a 250 ml. paper cup and stirred for 10 to 15 presence of by weight of potassium hydroxide. The seconds. The induction period, the period of rise of the 25 reaction Was considered complete when the infra-red foam and the height of the foam after rise were measured. spectrum of the product indicated the absence of hydroxyl The compositions and characteristics of the resulting groups. The catalyst residue was removed by filtration. foams are shown in Table IV. The following foaming composition was prepared.

TABLE IV Siloxane Boron tri- 2-.2-dl-poxyalkylene Trichlcrofluoride Example Vinyl Ether hydroxycopolymer monofiuroroin di- Induction Rise time, Height; of

phenyl type silimethane, g. ethylene period, sec. sec. foam, in. propane, g. cone surglycol, m1.

factant, g.

25 3,4-dihydr0-2H-pyran-(3A-dihy- 5 0.5 6 0.5 1O 9 tgio-zfi-pyran-zcarboxylate) 2s sis-lt-dmyam-zn-pymn-a a 0.5 a so 120 methyl) succinate: g. 27 Bis-(3,4-dihydro-2H-pyran-2- 5 0.5 5 0.5 55 65 methyl) adipatez20 g. Bis-(3,4-dihydro-2H-pyran-2- methyl) azelate; 2s 20 g. 5 0.5 5 0.5 110 as 5.5 29 20 g 5 0. 5 5 0.8 05 a5 4. 75 30 20 g 5 0.5 5 1.2 50 15 6.75

Bis-(3,4-dihydro-2Hpyran-2- methyl) sebacate: 31 20 g 5 5 5 1. 0 40 15 s. 32 20g 5 0.5 5 1.2 50 15 4.75 Bis-(3,4-dihydro-2H-pyrau-2- methyl) phthalate: 20 5 0.5 5 0.5 120 120 a 3 0.5 5 0.8 35 7.25 a 0.5 5 1.0 20 15 5.75 a 0.5 5 1.2 15 1 20 g 3 0.5 5 1. 2 20 10 5. 75 Bis-(3A-dihydro-2H-pyranmethyl) tumarate: 10 g 3 0.5 5 0.6 20 10 8 1 0.7 m1. of 10% BFs in polypropylene glycol M.W. 2025, dissolved in trlchloromonofluoromethane.

EXAMPLE 39 Trivinyl ether of propoxylated phenol-aldehyde condensa'te g 16 Butanediol-l,4-b1s-(3,4-d1hydro-2Hpyran-2-yl) ether was prepared by heating under reflux f0! 72 hours the 2"? dlp hydroxyphenol propane 8 following composition. Trichloromonofluoromethane g 12 G Siloxane oxyalkylene copolymer type silicone sur- Butanedio1-l,4-divinyl ether 995 facwnt Acrolein 840 Boron trifiuonde, 10% in diethylene glycol rn1 0.5 Hydroquinone 3 The product was fractionally distilled. A fraction of 1020 g. distilled over at ll0115 C. at 0.3 mm. to 0.4

mm. pressure of mercury. Measured molecular weight of the product was 250 compared to .a calculated value of 256.

A foaming composition containing the following ingredients was prepared.

The first four ingredients were mixed together for 10 seconds and then boron trifluoride catalyst was added with additional stirring. The composition foamed after an induction period of 42 seconds to form a flexible weak foam. When cured at C. for 10 minutes the foam was di- 7 5 mensiona'lly unstable.

is EXAMPLE 41 The tetravinyl ether of a polypropoxylated pentaerythritol was prepared as follows. The polypropoxylated pentaerythritol (Pluracol PeP 650) was treated with 14 EXAMPLES 56 to 59 A series of four foams were prepared, each of the fol-- lowing composition.

acetylene at 180-190 C. and at a pressure of 200-250 Vinyl ether g 18.75 p.s.i. in the presence of 5% by Weight of potassium hy- 2: 2-d1-p-hydhroxyphenol propane g 6.25 droxide. The reaction was considered complete when the T nchloromonofluoromethane g 5 infra-red spectrum of the product indicated the absence of 31101151116 oXyalkylene copolymef y slllcone hydroxyl groups. The catalyst residue was removed by factant g 0.1 filtration. 1O Catalyst The following foaming composition was prepared. 1 AS e ifi d in Table TABLE VI Amount of Induction Height of Example ,Vlnyl Ether Catalyst Catalyst, period, Foam, inches drops seconds 56 Buiimfigiol-lA-bis-(3,4-dihydro-2H-pyran-2- Fluoboric acid, 5%in diethylene glycol 150 4% y e 61'. 57 do Antinniny fluoborate approx. 4% in diethyl- 10 170 4 one g yc 5 do Fltigantimonic acid (HSbFt), 13% in hexyl 90 4% e 8!. 59 do Fluoantimonic acid (HSbF 33% in di- 15 530 2 ethylene glycol.

2:2-di-p-hydroxyphenyl propane g 6.7 Trichloromonofluoromethane g 8 is given i T bl VI, Siloxane oxyalkylene copolymer type silicone surfactant g 0.1 Boron 'trifiuoride, 2% in diethylene glycol ml 0.2 The first four ingredients were mixed together for 10 seconds and then the boron trifluoride catalyst was added with additional stirring. Theresulting foam was very 35 soft and flexible with a slightly tacky skin.

EXAMPLES 42 to A series of further foams were prepared, each of the following composition.

The above ingredients were mixed in a 250 ml; paper cup and the induction period and rise time of the resulting foams were measured. The description of the foams The catalyst concentration is expressed as percentage by weight of the active ingredient.

EXAMPLES to 71 A series of twelve foams were prepared from crude 3,4 dihydro 2H pyran-Z-methyl-(3,4-dihydro-2H- pyran-Z-carboxylate) employing different catalyst systems.

The following mixture was employed in each case.

40 Crude 3,4 dihydro 2H pyran 2 methyl-(3,4- Vmy1.ether 20 dihydro-ZH-pyran-Z-carboxylate) 20 f' f Propane 5 2:2-di-p-hydroxypheny1 propane 5 gf a ff f 5 Trichloromonofluoromethane 5 loxane oxya yene cope ymer ype s1 lcone Siloxane oxylalkylene copolymer type silicone surf n 5 factant 01 Catalyst (1) 7 As specified in Table V.

The above ingredients were mixed in a 250 ml. paper cup and the induction period and rise time of the resulting foams were measured. The description of the foams is given in Table V. The catalyst concentration is expressed as percentage by weight of the active ingredient.

The above ingredients were mixed together, and the specified catalyst added with stirring in a 250 ml. paper cup. The catalysts and description of the resulting foams are given in Table VII where catalyst concentration is expressed as percent by weight of active ingredient.

TAB LE V Amount of Induction Height of Example Vinyl Ether Catalyst Catalyst, period, Foam, inches drops seconds Bis-(3,4-dlhydro 2H-pyran-2-methyl) Antimony pentafluoride, 12% in diethylene 10 4% succinate. glycol. Bis-(3,4-dihydro-2H-pyran-2methyl) Antimony fluoborate, 40%-43% in water. 3 20 6 adipate.

Bis-(I?,4-dihydro-2H-pyran-2-methyl) Fluoboric acid, 48%50% in water 3 10 3% aze ate. Bis-(3,4-dihydro-2H-pyran-2-methyl) Antimony pentachloride, 10% in diethylene 20 45 3 sebacate. glycol. Butanediol-l,4-bis-(3,4-dihydro-2H-pyran- Phosphorus pentaflnonde, 10.5% in 15 4% -2-y1) ether. diethylene glycol. do Stannous fluoborate, 46%48% in Water 2 10 2 Dgginyl ether of polypropylene glycol of Hexafluorophosphoric acid, 65% in water---. 5 Very iast .W. 425. do Antimony pentafluoride, 12% in 6 Very fastdiethylene glycol. dn Fluoboric acid. 48%50% in water 1 Very fast do Ferric chloride, 10% in diethylene glycol 10 15 3% Tetravinyl ether of polypropoxylated Fluoantimonic acid (HSb ii), 65% in water. 5 15 3 pentaerythritol. do Stannous fluoborate, 46%-48% in water 12 240 3 dn Phosphorus pentafiuoride, 10.5% in 7 Fast 3 diethylene glycol. 55 dn Ferric chloride, 10% in diethylene glycol. 10 30 2% 17 EXAMPLE 1.13

A foaming composition containing the following ingredients was prepared.

18 EXAMPLE 121 The following foaming composition was prepared. Trivinyl ether of propoxylated phenol-aldehyde con- Butanediol-l,4 bis-(3,4 dihydro-2H pyran 2 yl) densate g ether g 10 2:2-di-p-hydroxyphenyl propane g 2.5 2:2-di-p-hydroxyphenyl propane g 3 Low molecular weight resinous condensate of epi- Low molecular weight resinous condensate of epichlorohydrin and 2:2-di p hy-droxy-phenyl prochlorohydrin and 2:2-di-p-hydroxyphenyl propane g 12.5 pane g-.. 12 10 Triohloromonofiuoromethane g 10 Trichloromonofluorornethane g 5 Siloxane oxyalkylene copolymer type silicone sur- Siloxane oxyalkylene coplymer type silicone surfactant -g 0.1 factant g 051 Boron trifluoride, 20% in diethylene glycol ml 0.2 Boron tnfluonde 10% m methylene glycol 15 The first five ingredients were mixed together for The first five ingredients were mixed for 10 seconds and gd g q il thenl the boron Lrrfluonde catalyst was the boron trifluoride catalyst was then added with addia F Wit .g z f T e composltlon foamed tional stirring. After an induction period of 39 seconds to orm a 6 Wea an excellent white foam with fine cell structure and a EXAMPLE 122 good skin was obtained.

EXAMPLES 114 T0 1x19 The following foaming composition was prepared.

A series of six foams were prepared containing 2:2-dif g ether of polypropoxylated pentaersgh' 10 p-hydroxyphenyl propane, a high viscosity epoxidized 2 -H drox be t o Cld 2 polyolefin Oxrron 2000) and different vinyl ethers uslng 5 i m 3 ig resinous condensate of S the following procedure. The vinyl ether, 2:2-di-p-hychloroh drin and drox hen 1 droxyphenyl propane, epoxidized polyolefin, the siloxane am y p y W y p 12 oxyalkylene copolymer type silicone surfactant and the g gggggfiflg fg ggzfigfl "5""5 10 trichloromonofluoromethane foaming agent were mixed '7. together. The boron trifiuoride catalyst was then added 5: 22; oxyalkylene copolymer type slhcone Sgur' 0 1 and and the mixture was poured mto a 250 ml. paper cup Boron trifluoride, 5% in diethylene glycol ml 02 and stirred for 10 to 15 seconds. The induction period, the period of rise of the foam and the height of the foam after rise were measured. The compositions and characteristics of the resulting foams are shown in Table X.

TABLE X 2:2-di- High Siloxane Boron trl- Induchydroxy viscosity oxyalkylene 'lrlchloro fluoride tion Rise Height, Ex. Vinyl Ether phenyl epoxidized copolymer monofluoro 10% in Di- Period, Period, in.

propane, g. polyolefin, g. type surmethane, g. ethylene see. sec.

factant, g. glycol, ml.

114-. 3,4dihydro-2H-pyran-2-methyl- (3,4-dihydro-2H-pyran-2-carboxylate), 20 g 5 5 0. 5 5 0. 5 4 20 9 115.-.. Bis-(3,4-dihydro-2H-pyran-2- methyl) adipate, 20 g 5 5 0. 5 5 0.5 4 40 7. 75 116 Bis-(3,4-dihydro-2H-pyranmethyl) succlnate, 20 g 5 5 0. 5 5 0.5 7 6O 6. 75 117 Bis-(3,4-dihydro-2H-pyran-2- methyl) azelate, 20 g 5 5 0. 5 5 0. 5 6 30 5. 5 118 Bis-(3.4-dihydro-2H-pyran-2- methyl) sebacate, 20 g 5 5 0. 5 5 0. 5 8 3. 75 119...- Bis(3,4dihydro-2H-pyran-2- methyl) phthalate, 20 g 5 5 0. 5 5 0. 5 7 35 5. 75

EXAMPLE 120 The following foaming composition was prepared.

The first five ingredients were mixed together for 10 seconds and then the boron tn'fiuoride catalyst was added with additional stirring. After an induction period of 12 seconds the composition foamed to form a flexible weak foam.

an induction period of 10 seconds to give a flexible weak foam.

EXAMPLE 123 The following foaming composition was prepared.

Tetravinyl ether of polypropoxylated pentaerythritol g 11.2 2:2-d-i-p-hydroxyphenyl propane g 3.8 Low molecular weight resinuous condensate of epichlorohydrin and 2:2-di-p-hydroxypheny-l propane g 10 Trichloromonofluoromethane g 5 Siloxane oxyalkylene copolymer type silicone surfactant g 0.1

Boron trifluoride, 2% in diethylene glycol ml 0.25

"The first five ingredients were mixed together for 10 seconds and then the boron trifiuonide catalyst was added with additional stirring. The composition foamed after an induction period of 30 seconds to produce a flexible soft weak foam.

EXAMPLE 124 The following two mixtures were prepared:

MIXTURE A Crude 3,4-dihydro 2H pyran 2 methyl (3,4-

dihydro-ZH-pyran-Z-carboxylate) 150 Epoxy novolak resin (Dow DEN 438) 50 Siloxane oxyalkylene copolymer type silicone surfactant 2.5 Trichloromonofluoromethane 50 Trimethoxyboroxine MIXTURE B Boron trifiuoride (10% in diethylene glycol) 7.5

Mixture B was added to Mixture A with rapid stirring. After 20 seconds, the mixed composition was poured into a mould and, after 80 seconds, foaming occurred to give an almost white foam of good structure. The foam had a core density of 1.4 lbs/ft. and needed a force of 4.9 lbs/sq. inch for 10% compression perpendicular to the direction of rise and 7.4 lbs/sq. inch force for 10% compression parallel to the direction of rise.

EXAMPLE 125 The following two mixtures were prepared:

Mixture A was blended with Mixture B with rapid stirring. After 20 seconds, the mixed composition was poured into a. mould, and foaming commenced after 73 seconds. A white foam with a tough skin resulted. The foam had a core density of 1.5 lbs/cu. ft. The force needed for 10% compression was 7.6 lbs/sq. in. parallel to the direction of rise and 5.5 lbs/sq. in. in perpendicular to it.

EXAMPLE 126 The following two mixtures were prepared:

MIXTURE A Crude 3,4-dihydro 2H py-ran 2 methyl (3,4-

dihydro-ZH-pyran-Z-carboxylate) 50 Vinyl cyclohexene dioxide 150 Siloxane oxyalkylene copolymer type silicone surfactant 2.5 Tric'hloromonofluoromethane 60 MIXTURE B Trimethoxyboroxine 6 Mixture A was blended with Mixture B with rapid stirring. After 10 seconds, the mixed composition was poured into a mould and foaming began after 91 seconds. The foam rose to yield a rather coarse white foam of 1.0 lb./cu. ft. density which did not shrink on cooling.

EXAMPLE 127 The following two mixtures were prepared:

MIXTURE A G Poly(ally1glycidyl ether) 150 Crude 3,4-dihydro 2H pyran 2 methyl (3,4-

dihydro-ZH-pyran-Z-carboxyl ate Siloxane oxyalkylene copolymer type silicone surfactant 2.5 Trichloromonofluoromethane 50 MIXTURE B Boron trifluoride (10% in diethylene glycol) 5 Mixture A was blended with Mixture B using high speed stirring. After 10 seconds the mixed composition was poured into a mould and foaming began after 30 seconds. A coarse foam of 1.4 lbs/cu. ft. core density resulted.

EXAMPLE 128 The following foaming composition was prepared.

The first four ingredients were mixed together for 10 seconds and then the boron trifluoride catalyst was added with additional stirring. After an induction period of 6 seconds the composition foamed to form a white flexible weak foam.

EXAMPLE 129 A foaming composition containing the following ingredients was prepared.

Butanedio1-1,4-bis (3,4 dihydro 2H pyran 2- yl)ether g 12 Low molecular Weight resinous condensate of epichlorohydrin and 2 Z-di-p-hydroxy-phenyl propane g 12 'Frichloromonofluoromethane g 5 Siloxane oxyalkylene copolymer type silicone surfactant g 0.1

Boron trifluoride, 20% in diethylene glycol ml 0.2

The first f our ingredients were mixed for 10 seconds and the boron trifluoride catalyst was then added with additional stirring. After an induction period of 48 sec-- onds a rigid foam was obtained.

EXAMPLES 130 TO 137 A series of eight foams were prepared containing ahigh viscosity epoxidized polyolefin (Oxiron 2000) and different vinyl others using the following procedure. The vinyl ether, the epoxidized olefin, the siloxane oxyalkylene copolymer type silicone surfactant and the trichlorornonofi-uoromethane foaming agent were mixed together. The boron trifluoride catalyst Was then added and the mixture was poured into a 250 ml. paper cup and stirred for 10 to 15 seconds. The induction period, the period of rise of the foam and the height of the foam after rise were measured. The compositions and characteristics of the resulting foams are shown in Table XI.

TABLE XI Siloxane Boron tri- High Viscosity oxyalkylene Trichlorofluoride 10% Induction Rise Height, Example Vinyl Ether Epoxidized copolymer monofiuoroin diethylene period, period, in.

polyolefin, g. type silicone methane, g. glycol, ml. see. sec.

surfactant, g.

3,4-dihydro-2H-pyran-2-n1ethyl-(3,4- dihydro-2Hpyran-Z-carboxylate):

20 g 10 0.5 5 0.25 2 2. 25 20 g 5 0. 5 5 0.25 10 40 2. 5 20 g 5 0.5 5 0.5 5 30 5. 75 Bis (3,4-diliydm-ZHQyranQ-methyl) 5 0.5 5 0. 5 7 20 5. 5

adipate: 20 g. Bis-(3,4-dihydro-2H-pyran-2-methyl) 5 0. 5 5 0. 5 5 50 6. 75

snccinate: 20 g. Bis-(3.4-dihydro-2H-pyran-2-rnethyl) 5 0. 5 5 0. 5 8 20 4. 75

azelate: 20 g. Bis-(3,4-dihydro-2H-pyran-2-n1ethyl) 5 0. 5 5 0. 5 10 5 sebacate: g. Bis-(3,4-dihydro-ZH-pyran-Z-methyl) 5 0. 5 5 0.5 5 15 3. 75

phthalate: 20 g.

EXAMPLE 13 8 The divinyl ether of polypropylene glycol of molecular weight 425 was prepared as follows. Polypropylene glycol of molecular weight 425 was treated with acetylene at 180190 C. and at a pressure of 200-250 p.s.i. in the presence of 5% by weight of potassium hydroxide. The reaction was considered complete when the infra-red spectrum of the product indicated the absence of hydroxyl groups. The catalyst residue was removed by filtration.

The following foaming composition was prepared:

Divinyl ether of polypropylene glycol of molecular weight 425 g 10 Low molecular weight resinous condensate of epichlorohydrin and 2 :Z-di-p-hydroxyphenyl propane g 15 Trichloromonofluoromethane g 5 Siloxane oxyalkylene copolymer type silicone surfactant g 0.1

Boron trifluoride, 10% in diethylene glycol ml 0.15

The first four ingredients were mixed together for 10 seconds and then the boron trifluoride catalyst was added with additional stirring. After an induction period of 12 seconds the composition foamed to form a flexible weak foam.

EXAMPLE 139 The following foaming composition was prepared: Trivinyl ether of propoxylated phenolaldehyde condensate 10 Low molecular weight resinous condensate of epichlorohydrin and 2 Z-di-p-hydroxyphenyl propane g 15 Trichloromonofluoromethane g 10 Siloxane oxyalkylene copolymer type silicone surfactant g 0.1

Boron trifiuoride, 10% in diethylene glycol ml 0.38

The first four ingredients were mixed together for 10 seconds and then the boron trifiuoride catalyst was added with additional stirring. The composition foamed to form a flexible weak foam.

EXAMPLE 140 The following two sets of ingredients:

Tris-(3,4-(1ihydro-ZH-pyran-Z-methyl) phosphate Bis-(3,4-dihydro-2H-pyran-2-methyl) 10 g.

adipate.

High viscosity epoxldized polyolefin 5 g 5 g.

(Oxir0n 2000).

Siloxane oxyalkylene copolymer type 0.5 g 0.5 g.

silicone surfactant.

Trichloromonoflnoromethane 5 g 5 g.

were mixed separately and then to each one was added with additional stirring 1.5 ml. of a solution containing 10% by weight of boron .trifluoride in diethylene glycol. The mixtures were then poured into 250 ml. paper cups. The characteristics of the resulting foams are as follows:

when mixed using heating when necessary. The composition was then cooled to room temperature and 12g. of trichloromonofluoromethane were added with stirring, then 1 g. of a solution containing 10% by weight of boron trifluoride etherate in glycol was added. A light, slow rising, resilient foam of uniform cell structure was obtained.

EXAMPLE 142 The following ingredients:

G. 3,4 dihydro 2H pyran-Z-methyl-(3,4-dihydro-2H- pyran-Z-carboxylate) 17 Polyvinyl chloride-polyvinyl acetate copolymer 3 Dioctyl phthalate 6 Siloxane oxyalkylene copolymer type silicone surfactant 2 2:2-di-p-hydroxyphenyl propane 2 were mixed using heating where necessary. The composition was cooled to room temperature and 10 g. of trichloromonofiuoromethane added with stirring. Then 1 g. of solution containing 10% by weight of boron trifiuoride etherate in glycol was added. After 20 seconds the composition foamed to produce a light coloured resilient foam of non-uniform structure.

EXAMPLE 143 The following ingredients:

G. 3,4 dihydro-2H-pyran 2-methyl-(3,4-dihydro-2H-pyran-Z-carboxylate) 18 2:2-di-p-hydroxyphenyl propane 2 Siloxane oxyalkylene copolymer type silicone surfactant 0.5 Trichloromonofiuoromethane 4 Ammonium chloride 10 were mixed and then 2 g. of a solution containing 10% by weight of boron trifluoride etherate in glycol were added. The composition foamed after 15 seconds to give a light weight dark foam of uniform cell size which was self-extinguishing by ASTMDl69259T.

EXAMPLES 144 TO 149 A series of six foaming compositions were prepared, the proportions of ingredients varying only in the amount of the amine and the boron trifluoride catalyst ingredients. A first mixture was prepared by dissolving 2:2-di-phydroxyphenyl propane in crude 3,4-dihydro-2H-pyran-2- methyl-(3,4-dihydro-2H-pyran-Z-carboxylate) at 100 C., cooling to room temperature and then adding the siloxane oxyalkylene copolymer type silicone surfactant and the distilled dimethyl tertiary amine derived from coconut fatty acids (A-rmeen DMCD). The second mixture consisted of trichloromonofluoromethane and a solution containing 10% by weight of boron trifiuoride in polypropylene glycol of 2025 molecular weight. The second mixture was added to the first mixture while stirring with a high speed mixer. After 10 seconds of stirring, the mixture was poured into a mould. The resulting foams were rigid and had a density of approximately 2 pounds per cubic foot. The compositions and induction period and rise time are shown in Table XII. It can be seen that by increasing the proportion of the amine ingredient, both the induction period and rise time can be increased thus providing control of the foaming process.

the generic formula our Hf) ?Hz 1 H0\ /CH-X O O in wherein n is an integer having a value of at least two and X is a linking group having a valence equal to n;

(B) a. material reactive with the ethylenic double bonds of said vinyl ether and selected from the group consisting of (BB) compatible phenolic compounds;

(BC) compatible epoxidized materials containing at least one epoxide group per molecule; and

(BD) mixtures of (BB) and (BC);

(C) an acidic catalyst capable of promoting the polymerizing reaction between (A) and (B) and selected from the group consisting of strong proton-donating acids and Lewis acids; and

(D) a foaming agent vaporizing at the temperature of reaction of (A) with (B).

2. A foamed cellular polymeric material as claimed in TABLE XII Crude 3,4-dihy- Siloxane oxyal- Dimethyl terti- Boron trifluoride dro-ZH-pyran-Z- 2:2-di-p-hydroxkylene copolyary amine de- Trichloromonoin polypro- Induction Rise Example methyl-(3, 141% ypheuyl pro mer type silicone rived from fluoromethane, pylene glveol Period Period hydro-2H-pyranpane, grams surfactant, coconut fatty grrnas 20 25, seconds seconds Z-carboxylate), grams acids, grams grams grains 20c 50 2.0 50 5. c 10 200 50 2. 0 0. 25 50 5. 5 15 11 c 50 2. 0 0. 75 50 6. 5 27 20 200 50 2. 0 1. 50 s. 5 30 20 200 50 2. o 1. 75 50 10. 0 20 200 50 2. o 2. 25 50 12. 0 23 EXAMPLE 150 claim 1 wherein the proportions of the ingredients of the foamable com osition are such that: The followin 1n redients: p

g g G. (BB) the number of hydroxyl groups provided by the Crude 3,4-dihydro-ZH-pyran-Z-methyl-(3,4-dihydr0- Phenom ComPmmd than the l 2H pyran 2 carbOXy1ate) 232 -g groups p d y the yl t 2:2-di-p-hydroxyphenyl propane 58 an Low molecular weight resinous condensate of epi- (BD) number of hYdmXYI groups provided by the chlorohydrin and 2:2 di p hydroxyphenyl phenolic compound 15 not greater than about 75% pane 190 Of the ombined number of -Hc=c and Siloxane oxyalkylene copolymer type silicone surfacl groups Provided l the vinyl ether and tam 2 epoxidized material, respectively.

3. A foamed cellular polymeric material as claimed were mixed for 2 minutes using a high speed stirrer and then 65 g. of trichloromonofiuoromethane were added. Stirring was continued for an additional 30 seconds and 6 ml. of a solution containing 20% by weight of boron trifluoride in diethylene glycol were added. The composition foamed immediately to give a white foam. When the procedure was repeated using the same ingredients but adding to the catalyst solution 10 ml. of a solution of a boron trifluoride-amine complex the induction time was increased to 20 to 30 seconds permitting better control of the foaming process. The following boron trifluorideamine complexes were found to be effective.

(1) Boron trifiuoride-triethanolamine complex, 20% by weight in methylalcohol solution.

(2) Boron trifluoride-pyridine complex, 7% by weight in glycol monoethylether solution.

(3) Boron trifluoride-triisopropanolamine borate complex, 20% by weight in butyl alcohol solution.

(4) Boron trifiuoride-trioctadecylarnine complex, 5%by weight in xylene solution.

in claim 1 wherein the material reactive with the ethylenic double bonds of the vinyl ether ingredient of the foamable composition is a compatible phenolic compound.

4. A foamed cellular polymeric material as claimed in claim 3 wherein the proportions of the ingredients of the foamable composition are such that the number of hydroxyl groups provided by the phenolic compound is less than the number of HC=CH- groups provided by the vinyl ether.

5. A foamed cellular polymeric material as claimed in claim 1 wherein the foamable composition comprises 3,4- dihydro 2H pyran-2-methyl-(3,4-dihydro-2H-pyran-2- carboxylate) as a vinyl ether ingredient.

7 6. A foamed cellular polymeric material as claimed in claim 2 wherein the foamable composition comprises 3,4- dihydro 2H pyran-Z-methyl-(3,4-dihydro-2H-pyran-2- carboxylate) as a vinyl ether ingredient.

7. A foamed cellular polymeric material as claimed in 5 claim 3 wherein the foamable composition comprises 3,4-

25 dihydro 2H pyran-Z-methyl-(3,4-dihydro-2H-pyran-2- carboxylate) as a vinyl ether ingredient.

8. A foamed cellular polymeric material as claimed in claim 4 wherein the foamable composition comprises 3,4- dihydro 2H pyran-2-methyl-(3,4-dihydro-2H-pyran-2- carboxylate) as a vinyl ether ingredient.

9. A foamed cellular polymeric material as claimed in claim 1 wherein the foamable composition comprises bis- (3,4-dihydro-ZH-pyran-Z-methyl)phthalate as a vinyl ether ingredient.

10. A foamed cellular polymeric material as claimed in claim 7 wherein the foamable composition comprises 2:2-di-p-hydroxyphenyl propane as a phenolic ingredient.

11. A foamed cellular polymeric material as claimed in claim 8 wherein the foamable composition comprises 2:2-di-p-hydroxyphenyl propane as a phenolic ingredient.

12. A foamed cellular polymeric material as claimed in claim 1 wherein the acidic catalyst of the foamable composition is at least one member selected from the group consisting of boron trifluoride and boron trifluoride etherate.

13. A foamed cellular polymeric material as claimed in claim 1 wherein the foaming agent of the foamable composition is a chlorofluorocarbon.

14. A process which comprises mixing (A) at least one polymerizable cyclic vinyl ether of the generic formula wherein n is an integer having a value of at least two and X is a linking group having a valence equal to n;

(B) a material reactive with the ethylenic double bonds of said vinyl ether and selected from the group consisting of (BB) compatible phenolic compounds; (BC) compatible epoxidized materials containing at least one epoxide group per molecule; and (BD) mixture of (BB) and (BC);

(C) an acidic catalyst capable of promoting the polymerizing reaction between (A) and (B) and selected from the group consisting of strong protondonating acids and Lewis acids; and

(D) a foaming agent vaporizing at the temperature of reaction of (A) with (B),

and allowing the mixture naturally to self-expand into a foamed cellular polymeric material.

15. A process as claimed in claim 14 wherein the proportions of the ingredients of the expandable mixture are such that (BB) the number of hydroxyl groups provided by the phenolic compound is less than the number of HC=CH groups provided by the vinyl ether; and (BD) the number of hydroxyl groups provided by the phenolic compound is not greater than about of the combined number of HC=CH-- and epoxide groups provided by the vinyl ether and epoxidized material, respectively.

References Cited by the Examiner UNITED STATES PATENTS 2,998,415 8/1961 Geiser 260-911 3,051,665 8/ 1962 Wismer 2602.5 3,128,258 4/1964 Doedens et al. 2602.5 3,232,892 2/1966 Fisher 2602.5

MURRAY TILLMAN, Primary Examiner.

M. FOELAK, Assistant Examiner. 

1. A FOAMED CELLULAR POLYMERIC MATERIAL WHICH IS REACTION PRODUCT OF A FORAMABLE COMPOSITION COMPRISING (A) AT LEAST ONE POLYMERIZABLE CYCLIC VINYL ETHER OF THE GENERIC FORMULA 